RESUME

Name : SANJAY PRAKASH AGRAWAL

Age : 45 years (3rd July, 1970)

Contact details : sanjaypagrawal@gmail.com , 09412601911(P) / 08392947803(O)

Passport Details : F 8755498, Issued from BAREILLY on 25.08.2006, valid up to 24.08.2016

Personal details : Married and blessed with 2 Sons (aged: 16+ years and 9+ years)

Educational Qualification : 1. [1991-1995] B.Tech in Mechanical Engineering from Aligarh Muslim University, Aligarh with 72% marks.

2. Complete “Post Graduate Diploma in management” in 2004 from University of Indianapolis, USA; through “B-School” which was arranged by the TCL at site.

Total Working Experience : 19 years (Working for M/s TATA Chemicals Limited, Fertilizer Business, Babrala, [UP], India since Sep'1996.)

Current CTC : 23 L per annum (18 L + 5 L other facilities like furnished residence, medical, school fee and other facilities in town ship)

Current responsibilities : Sr. Manager- Reliability & Planning; I am responsible for the functioning of followings sections-

1. Reliability (Inspection cell),: 3 Engineers + 3 officers

Develop, review and adherence of Inspection plans (like ; Vibration schedule, Piping Inspection, Steam trap inspection, Review of Risk Based Inspection plan, & other NDT activities)

2. Maintenance Planning section: 5 Mechanical Engineers direct reporting + Electrical & Instrumentation Planners indirect reporting

Shut down planning (Anchor for S/D Planning at Unit Level)

CAPEX & Revenue Budget preparation for Mechanical Function

Detailed planning for Budgeted, CAPEX jobs for Mechanical.

Detail planning ( Material, Gant Chart, QAP, Safety Analysis) for all Shut down jobs of Mechanical + Co-ordinate for others

Skill Evaluation & Training

Maintenance contracts & Hiring of services for onetime jobs

Long Term Asset management Plan

Root Cause Analysis

3. Work shop, Mobile cranes & painting: 7 officers + 20 Contractor staff

Operation & maintenance and mobile cranes,

Machine Tools in work shop.

Restoration painting across the Unit around 35000 M2/Per year.

Additional Responsibilities:

1. Leading the team implement the Asset Integrity element requirement to Roll-out Process Safety Management system at Babrala Unit.

2. Location Anchor for the Implementation of Job Safety Analysis requirement at Babrala Unit in line with TATA group Safety Standard.

3. Development of Procurement Guide lines & Implementation at Unit level to optimise Inventory level

Working Experience Summary:

Positioning summary:

Position Duration Working area

Sr. Manager 2013 onward Reliability & Planning (Inspection & Condition monitoring cell, Maintenance Planning & Mechanical Workshop)

Manager 2006-2013 Performance Improvement Program (Manthan), Morocco on deputation (2+ yr), Project procurement, Maintenance & Nigeria (NCIL) on deputation (1+ Yr)

Deputy Manager 2002-2006 Mechanical maintenance, Performance Improvement Program

Assistant Manager 1997-2001 Maintenance, Procurement

GET 1996-97 Mechanical maintenance

Functional exposure summary:

Function Area Period Location Key activities/ Responsibilities

Remarks

Maintenance

Routine maintenance Ammonia 2 years

TCL, Babrala India

Maintenance of All type pumps used in Ammonia, Urea, and O&U area

Maintenance High Pressure exchangers & Vessels in Ammonia, Urea & O&U

Urea 1 year

Offsite & Utilities 1 year

Product Packaging 1 year Maintenance of Material handling systemLike ( Belt conveyor, portable conveyor, slat conveyor, stitching machine, truck loader etc)

Work shop 1 year

Operation and maintenance of cranes Operation and maintenance of machine tools

Fabrication Shop Fabrication jobs in routine maintenance & modifications

Central Planning & PM cell

3 years

RBI & LAMP Goal setting for Mechanical team Contract management Central spares management CAPEX and Revenue budget preparation and

trackingShut down maintenance

Shut down planning & Execution in Shut down

6 Ammonia4 Urea

Specific jobs in maintenance

1 year Repairing of S-50 Ammonia converter

It was repaired 2 times at site

6 Months Replacement of 2.5 KM underground ring water header

MaterialsRoutine Procurement

2 yrs

Technical spec verification, RFQ preparation, negotiation, ordering and follow-up for delivery

Vendor grouping, NPA handling and item code standardization as special projects

Project procurement

6 months Negotiation, ordering and transportation of material for Customized Fertilizer project

Performance improvement program (Manthan)

Reduction of NPA & Stores Inventory

6 months

Identify the NPA items in revenue inventory and installed assets in facilities

Reduction in Specific energy consumption

Study the Process flow diagrams and identify the energy saving scheme to reduce variable cost/ per ton of Urea production

International exposure (3+ yrs)

Technical controller

2 yrs IMACID, Morocco

Technical controller on behalf of India partners Implement the Good Engineering practice in

maintenance Develop RBI & Long Term Asset management

plan Establish Root cause analysis in maintenence

Technical Adviser 14 months

NCIL, Nigeria

Gap analysis in Maintenance practices Develop maintenance & Inspection systems Performance tracking system Use of quality tools in maintenance (RCA &

FMEA)

Additional Professional Exposures

Process Safety Management

Additional along with functional working

TCL, Babrala, India

Safety Culture enabler team Lead Asset Integrity team to develop and

implement the maintenance & inspection philosophy in line of PSM guide lines(across the maintenance).

Tata Business Excellence Model

Part of internal assessment team in 2007 Member for external assessment team

ISO Qualified for Internal audit in 2005Legal Compliance Compliance of legal requirement Six Sigma (Green Belt)

One project to” reduction of unplanned jobs in Maintenance” in year 2005-06

FMEA Critical equipments & Maintenance Processes (ISO)

Risk Assessment Leader of Risk assessment carried out for the all routine activities in maintenance

BBS Leading member to introduce BBS at location

Details of Working Experience:

International Assignments (3.5 Years)

NCIL, Nigeria (14 months: June’11 to July’12):

Tata chemicals has signed “Technical service agreement” with M/s Notore Chemicals & Industries limited, Nigeria ( only fertilizer Comp in Sub Sahara region) to provide technical support and develop operation & Maintenance system for smooth operation. Key activities of the agreements are as follows;

Gap analysis & develop the system for performance tracing

Suggest corrective action for existing problems and long term action

Develop systems for sustained production

Sharing of Technical knowledge and system for in-house technical skill development

Lead maintenance jobs for better maintenance practice

Training & use of quality tools in maintenance

IMACID, MOROCCO (2+ years: August 2007 to October 2009):

Tata chemicals Limited have many international projects (Owned or Joint Venture) and I was selected for international projects as Indian representatives for INDO MAROC PHOSPHORE S.A. (IMACID), Morocco from August 2007 to October 2009.

It is a joint Venture of OCP group (Morocco), Tata Chemicals Limited & CFCL (India) to produce Sulphuric acid ( 3800 TPD) and Phosphoric Acid (1400 TPD).

I have been there for more than 02 years to look after the maintenance function as the representative of both the Indian companies.

I was responsible for the followings:

1. Technical controller for all maintenance (Mechanical, Electrical, Instruments & Civil) functions, and involved in the procurement, critical maintenance activities, shut down planning, and development of the required improvements in the maint. Procedures

2. Detailed Planning for all critical jobs in Mechanical Maintenance.3. Analyze future risk & plant reliability, and prepare LAMP (long term asset management plan). I was also

responsible for the implementation of inspection and replacement plan as per the LAMP. 4. Responsible for the routine and shut down inspections planning and carryout required inspection.5. Failure analysis along with Production and Maintenance dept.

Specific Tasks handled:

Preparation of Risk based inspection plan for Sulphuric Acid and Phosphoric Acid plant. Review of all inspection plan and record preparations. Inspection and maintenance of Waste heat boiler in SAP to avoid frequent leakage problem. Leading member of team for the repairing of super heater.

India Operation (15+ Years):

MECHANICAL MAINTENANCE (11 years+ 1 year GET ):

Special Tasks/ Projects Handled in maintenance (1 year) :

I have spent around 1 year for handling various specific maintenance jobs, as mentioned below;

1. Replacement of underground service water header 2.5 km, in green belt area.2. I have lead S-50 (2nd ammonia converter) repairing team along with L&T engineer in 2010; Bottom potion of

this converter was having multiple ir-repairable cracks at different locations. So shortening of converter was done at site (1st time in India), and it took around 5 months against the planned schedule of 6.5 months. It is 3 layered, 3 mtr. OD & 25 mtr. long equipment and its weight is 270MT.

3. I was a leading member of the team for AMMNOIA CONVERTOR 3rd Seam repairing job in 2004. This ammonia Converter is made by 48.5 mm thick 3 layers of P22 material (Total wall thickness is 145.5 mm). Approximate 700x2500 mm piece was replaced at site as multi cracks were found at various locations in the wall.

4. Both Urea Stripper (weight=75 MT) reversals in Urea Plant as tube ends were damaged at solution inlet side.5. Additional 5 Trays were provided in the bottom portion of both Urea Reactors in Urea Plant to increase the

efficiency. Central planning and Spares Management (3 years ):

I have established central spares management cell (after getting experience in Materials Management) in maintenance to avoid duplicate procurement and focused approach for better inventory control.

1. Procurement of major equipments and jobs under CAPEX.

2. Contract management.

3. Preparation of Revenue and Capital Budget and its review.

4. Planning for major Maintenance Issue in the complex and Major maintenance planned jobs.

5. Shut down planning (material, services, Preparation of Procedure cum check list,Risk assessment for all major job)

6. Co-ordination with Purchase section for required materials by all users and ensure the procurement of general consumable items for mechanical department.

7. Take additional charge for routine jobs in field also in absence of Manager- Mechanical & Condition Monitoring Cell.

Specific Tasks Handled: I have lead team for standardization of all Mech. Item codes (around 22000 items codes) to complete

technical information required for the procurement. Complete Vendor grouping and link all material codes with unique vendor group. Review of duplicate item codes

Review of all items to identify the NPA (obsolete items, extra qty available) and explore the potential buyers for the same.

I was leading member to define Maintenance process in ISO as per the EPM guide lines. VED analysis of all mechanical items

Shut Down Experience (9 shut downs: 6 Ammonia & 3 Urea):

Ammonia Plant ( 6 shut downs):

Annual Turn around Planning (Material, Man power and other resources) 3 times and Job Execution in 6 ATR.

Static Equipments

1. Partial Replacement of Cold Collector2. Primary reformer / Secondary reformer/ Waste heat recovery Boilers/ G.V. towers.3. All Exchangers of Ammonia Plant (Straight Tube fixed tube sheet, Straight tube Floating tube sheet, U

tube Bundle)4. Many a time held responsibility of opening & box-up of high pressure (working pressure>110 kg/cm2)

exchanger of ammonia plant. End covers of these exchangers are opened with “pneumatic bolt tensioning device” only.

Urea Plant (3 shut downs):

I have worked 4 years in Urea plant Annual Turn Around jobs and handled jobs of following equipments:

Maintenance of Urea Reactor, Maintenance of Urea Stripper (Titanium Welding), Modification in Tube to Ferrules fit-up to avoid bypassing. Maintenance of Carbamate condensers Maintenance of other exchanger

Routine Maintenance Experience (6 years):

Ammonia Plant :-Headed Ammonia plant mechanical Maint. Team. and Responsible for the below: Day to day plant Maintenance. (Preventive / Predictive & Breakdown Maintenance) Bar chart preparation

& RCA of the failures. Rotary Equipments

1. Maintenance of Single Stage pumps / Mechanical Seals / Reciprocating Pumps2. Over Hauling of 11 Stages Horizontal casing Boiler Feed Water pump & 6 stages Vertical Naphtha

Transfer pump. Specific Task Handled:

Over Hauling of 11 Stages Horizontal casing Boiler Feed Water pump & Over hauling of 6 stages Vertical Naphtha Transfer pump. Overhauling of GV circulation pumps ( Double suction, single stage centrifugal pump)

Urea Plant :- Assistant Manager in Urea plant mint. Team. and was responsible for the following:

Day to day maintenance in Urea Plant. Maintenance of High Speed (16000 RPM) Carbamate Solution transfer pump in Urea Plant. Maintenance of Single Stage pumps / Mechanical Seals. Maintenance of high pressure Reciprocating type Ammonia feed pump.

Product Packaging Plant :- Assistant Manager in Product Packaging plant maint.and responsible for the following:

Belt Conveyors

Slat Conveyors

Stitching Machines

Operation & Maintenance of Locomotive Engine

Offsite & Utility area : Assistant Manager in O&U mechanical Maint. Team. and held responsibilities as mentioned below :

Was responsible for Day to day maintenance of Off-sites and Utilities Plant Area (Cooling Tower,

D.M.Plant area, Power Plant, Service Boiler, Naphtha Handling, Ammonia Storage & ETP area). Major Jobs handle in O&U area are as follows:

Maintenance of cooling water Pump (double suction, single stage centrifugal pump) Maintenance of Double Stage Reciprocating Compressor. Maintenance of Cooling Tower Fans and Gear Box. Maintenance to multistage Naphtha transfer pumps Rubber lining Jobs in DM Plant area. Over Hauling of multistage Naphtha transfer pumps

Work Shop & Fabrication Shop: Worked as Assistant Manager and held responsibilities as mentioned below :

Was responsible for day-to-day fabrication and erection jobs for maintenance / Modification jobs. Was In-Charge of Mechanical Work shop and responsible for the day to day machining jobs and learn

about repairing of equipment parts by welding and machining Responsible for Operation and Maintenance of Mobile cranes (Hydra, 35T & 50T OMEGA crane and 75 T

& 100T crawler cranes).Specific Task Handled:

I was fully involved in re-tubing of Straight Tube Heat exchanger and U-tube bundle of the exchanger

Performance Improvement Program ( 06 Months):

I worked as Deputy Manager- Manthan before my selection for International Projects.

Tata Chemicals had developed a methodology to optimize the operation cost and increase the plant efficiency. A separate dept. (Manthan) is established to work on this methodology for all Techno commercial study of existing plant / activities and identify the improvement to reduce deficiencies in the system.

I was leading member of team working for “Reduction in energy consumption” for per Ton of Urea production.

MATERIALS DEPARTMENT (2.5 years):

I had Worked as Assistant Manager- Purchase section (in charge- purchase section) and reported to Manager –Materials.

I was responsible for the followings routine works:

Maintaining Minimum inventory levels of Critical chemicals, Day-to-day Indigenous procurement and general Stock Items Review of RFQ, Orders, and ARC for the correctness of technical information & commercial terms. Procurement (Planning, Order preparation and Follow up with vendors) for material required in Shut Down. ABC and VED analysis (to decide reorder & minimum stock qty of GST items) Inventory control plan along with user dept

Specific Tasks Handled: Ensure the implementation of Purchase related reports and transaction in MM module of SAP. Up-date vendor database for correctness of addresses and other regal information (Sales tax no. etc) Develop a system to track GST items on daily basis for better control. Gathered business interest of vendors and start vendor grouping. Procurement for Customized Fertilizer Project ( specially in-bond logistic for project material from different

location)

Other Professional Achievements:

Certified PSM Auditor Certified ISO Auditor. Certified Six Sigma Green Belt (% of planned jobs in maintenance) holder from Motorola University, USA. Qualified for External assessor for Tata Business Excellence Model (TBEM). I leading member to rollout Behavior based safety concept in Babrala. I was leader for Risk-assessments carried out first time in Mechanical.